Polyurethane foam having a flame retardant oligomeric phosphate ester

ABSTRACT

Flame retardant oligomeric phosphate ester compositions having the structural formula: ##STR1## are prepared, wherein R is C 1  -C 10  alkyl or haloalkyl, R 1  and R 2  can be the same or different and are hydrogen, C 1  -C 10  alkyl or haloalkyl and n is an integer from zero to about 10. 
     The method of preparing the compositions comprises reacting P 2  O 5  with a trialkyl or tris(haloalkyl)phosphate in the presence of about 0.01% to about 5% of a phosphite at a temperature from about 0°-200° C. A polyphosphate ester having P--O--P bonds is formed which is then reacted with an epoxide to yield the oligomeric phosphate ester flame retardant compositions. 
     Alternatively, a method of preparing similar compositions comprises reacting P 2  O 5  with a trialkyl or tris (haloalkyl)phosphite at a temperature from about 0° C. to about 200° C. A mixed polyphosphate-polyphosphite ester having P--O--P bonds is formed which is then oxidized to yield a polyphosphate having P--O--P bonds; which is then reacted with an epoxide to yield the oligomeric phosphate ester flame retardant compositions.

This is a division of application Ser. No. 318,288 filed Nov. 4, 1981, now U.S. Pat. No. 4,382,042.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates, in general, to flame retardant oligomers, and particularly concerns a method of preparing flame retardant oligomeric phosphate esters.

2. The Prior Art

Oligomeric phosphate esters are known and are described in U.S. Pat. No. 3,767,732. U.S. Pat. No. 3,767,732 patent discloses compositions having the structural formula: ##STR2## wherein a stands for 1 or 0, n stands for a number between 0 and 4, R₁ stands for at least one halogenated hydrocarbon radical and at least one hydroxylated radical of the structural formula: ##STR3## and R₂ stands for a radical of the structural formula: ##STR4## The substituents R₃ and R₄ respectively stand for a hydrogen atom or a hydrocarbon radical having from 1 to 6 carbon atoms and being halogen substitued, if desired, and m stands for a number between 1 and 10.

The method of preparing the compositions of U.S. Pat. No. 3,767,732 comprises reacting a compound of the structural formula: ##STR5## wherein R₅ is chloroethyl or 2,3-dibromopropyl and b is 0 or 1; in the presence of between about 0.1 and 2 percent of a phosphorus acid stabilizer and between about 0.1 and 2 percent of disodium phosphate with a polyphosphoric acid or a mixture thereof with P₂ O₅. A reaction mixture of partially esterified polyphosphoric acids is prepared by this step. The reaction mixture is then further reacted with an epoxide having the structural formula: ##STR6## wherein R₃ and R₄ are as defined above; until said partially esterified polyphosphoric acids are completely esterified. The product is a reactive flame retardant having hydroxyl numbers from about 100 to 300 milligrams of KOH per gram of product.

It is known that reactive flame retardants are undesirable for flexible polyurethane foams. They are detrimental to the flexibility of the foams and can cause other undesirable side effects to the foam properties.

SUMMARY OF THE INVENTION

In accordance with the present invention, flame retardant oligomeric phosphate esters having hydroxyl numbers from 1 to about 25 milligrams of KOH per gram of product are prepared. These oligomers have excellent flame retardancy characteristics as additive flame retardants for flexible polyurethane foams. Their additive nature prevents damage to the physical characteristics of flexible polyurethane foams. Furthermore, their oligomeric nature substantially reduces leaching of the flame retardant from the foam; thereby obviating a common undesirable characteristic of non-oligomeric additive flame retardants.

The method of the present invention comprises first reacting P₂ O₅ with a trialkyl or tris(haloalkyl)phosphate in the presence of about 0.01% to about 5% of a phosphite at a temperature from about 0° C. to about 200° C. The reaction product is a mixed polyphosphate ester containing P--O--P bonds which is then reacted with an epoxide.

Alternatively, P₂ O₅ is first reacted with a trialkyl or tris(haloalkyl)phosphite at a temperature from about 0° C. to about 200° C. The reaction product is a mixed polyphosphate-polyphosphite ester containing P--O--P bonds; which is oxidized with air or oxygen to yield a polyphosphate ester having P--O--P bonds; which is then reacted with an epoxide. A Lewis acid catalyst or an alcohol or both are employed during the epoxide reaction to insure complete reaction of latent acidity groups. Volatile materials are removed following the epoxide reaction.

DETAILED DESCRIPTION OF THE INVENTION

The oligomeric phosphate ester compositions of the present invention have the structural formula: ##STR7## wherein R is C₁ -C₁₀ alkyl or haloalkyl, R¹ and R² can be the same or different and are hydrogen or C₁ -C₁₀ alkyl or haloalkyl and n is an integer from zero to about 10.

Exemplary R groups include but are not limited to the following:

    ______________________________________                                         CH.sub.3           CH.sub.2 CHBrCH.sub.2 Br                                    C.sub.2 H.sub.5    CH.sub.2 CHClCH.sub.2 Cl                                    C.sub.n H.sub.2n+1; n=0-9                                                                          ##STR8##                                                    ##STR9##                                                                                          ##STR10##                                                  CH.sub.2 CH.sub.2 Br                                                                               ##STR11##                                                   ##STR12##                                                                     ______________________________________                                    

Exemplary R¹ and R² groups include but are not limited to the following:

    ______________________________________                                         H          CCl.sub.3    CH.sub.2 CH.sub.2 Cl                                   CH.sub.3   CH.sub.2 Br  CHCCl.sub.2                                            CH.sub.2 CH.sub.3                                                                         CHBr.sub.2   CHClCH.sub.2 Cl                                        CH.sub.2 Cl                                                                               CH.sub.2 CCl.sub.3                                                                          CH.sub.2 OCH.sub.2 CHClCH.sub.2 Cl                     CHCl.sub.2 CH.sub.2 CHCl.sub.2                                                                         CH.sub.2 OCH.sub.2 CHBrCH.sub.2 Br                      ##STR13##                                                                                 ##STR14##                                                          ______________________________________                                    

The method of preparing the oligomeric phosphate esters of the present invention comprises first reacting P₂ O₅ with a trialkyl or tris(haloalkyl)phosphate having the structural formula: ##STR15## wherein R is the same as defined above.

This reaction is conducted at a temperature from about 0° C. to about 200° C. in the presence of about 0.01% to about 5% of a phosphite having the structural formula:

    P(OR).sub.3                                                (III)

wherein R is the same as defined above.

Alternatively, P₂ O₅ can be reacted with a trialkyl phoshite having the structural formula (III) at a temperature from about 0° C. to about 200° C. The product is then a mixed polyphosphate-polyphosphite ester having P--O--P bonds which is oxidized by reacting with air or oxygen at a temperature from about 0° C. to about 200° C.

The reaction product is a polyphosphate ester having P--O--P bonds which is then reacted at a temperature from about 0° C. to about 200° C. with an excess of an epoxide having the structural formula: ##STR16## wherein R¹ and R² are the same as defined above. The excess epoxide insures complete reaction of all P--O--P bonds. This step can be carried out at elevated pressure to prevent loss of a volatile epoxide.

A Lewis acid catalyst or an alcohol or both are employed in amounts from about 0.01% to about 5% during the epoxide reaction to insure complete reaction of latent acidity groups.

Suitable Lewis acid catalysts include but are not limited to the following:

    ______________________________________                                         Aluminum Chloride                                                                               Boron Trifluoride Etherate                                    Tetra(Isopropyl)Titanate                                                                        Boron Trifluoride                                             Stannous Octoate Zinc Chloride                                                 Magnesium Chloride                                                                              Antimony Trichloride                                          Titanium Tetrachloride                                                         ______________________________________                                    

Suitable alcohols include but are not limited to the following:

    ______________________________________                                         CH.sub.3 OH      CH.sub.3 (CH.sub.2).sub.n OH; n = 2-10                        C.sub.2 H.sub.5 OH                                                                              (BrCH.sub.2).sub.3 CCH.sub.2 OH                                ##STR17##       φCH.sub.2 OH                                              ______________________________________                                    

Following the epoxide reaction, volatile materials are removed from the reaction product. This can be accomplished by vacuum stripping, nitrogen sparging, CO₂ sparging, dry air sparging, or combined vacuum and inert gas sparging.

The following equations (1) and (2) are representative of the reaction: ##STR18## wherein R, R¹, R² and n are the same as defined above, or alternatively: ##STR19## where R, R¹, R² and n are as defined above and m is 0 or 1.

Reactants utilized in the method described above are generally employed in suitable ratios to give a product with the desired %P, %Cl, viscosity, and oligomeric composition. The ratio of P₂ O₅ to trialkyl phosphate or tris(haloalkyl)phosphate, or alternately the ratio of P₂ O₅ to trialkyl or tris(haloalkyl)phosphite, can be varied over a wide range. A variety of compositions can be prepared by altering the stoichiometry of reagents.

Reaction times can vary over relatively wide ranges and can easily be determined by one skilled in the art. Factors affecting reaction time include reactant and catalyst concentrations and temperature. Increases in temperature and catalyst concentration result in decreased reaction times. Typical reaction times are from about 1 to about 30 hours for each step.

The method described above can conveniently be effected by introducing the individual reactants and catalyst into any reaction zone that can be heated to the reaction temperature. The zone is generally provided with a condenser for removal of volatile components. A thermometer, thermocouple or other conventional means can be used to monitor temperature. The reaction can be carried out in a continuous or batch-type system as desired.

The products of the reaction are generally purified by removal of volatiles. This can be accomplished by conventional techniques.

The identification of products can be achieved by infrared spectra, ¹ H nuclear magnetic resonance spectra and ³¹ P nuclear magnetic resonance spectra and elemental analysis.

Typical yields of the above-described method of the present invention are about 100% based on P₂ O₅.

The hydroxyl number of the products is generally from about 1 to about 25 milligrams of KOH per gram of product. Accordingly, the products are essentially non-reactive in flexible polyurethane foams.

Illustrative of the compounds corresponding to structural formula (I) which can be prepared by the method of the present invention are: ##STR20## Where n is as defined above. Branched oligomers of the foregoing idealized structures may be also be present.

The products of the present invention are useful for various flame retardant applications. They are particularly suited, however, for flame retarding flexible polyurethane foams.

The present invention will be more fully illustrated in the Examples which follow:

EXAMPLE 1

A reactor equipped with an agitator, thermometer, gas inlet and reflux condenser was charged with 1000 g of tris(2-chloroethyl)phosphate and 10 g of tris(2-chloroethyl)phosphite. The solution was warmed to 50° C. and 200 g of phosphorus pentoxide was added, with the exclusion of moisture and air. The slurry was then heated to 110°-120° C. until the phosphorus pentoxide dissolved. Two grams of isopropyl alcohol was added, and ethylene oxided was introduced to the mixture at 110°-120° C. until reaction ceased. This was indicated by strong reflux of ethylene oxide on a dry ice condenser. Two more grams of isopropyl alcohol and two grams of stannous octoate were added and ethylene oxide was introduced to the solution at 110°-120° C. until the reaction ceased. The product was then stripped at 50° C. and 5 mm of Hg, yielding 1457 g of a water white liquid with a viscosity of 1100 cps (at 25° C.) and an acid number of 0.8 mg KOH/g. The product had a hydroxyl number of 12 mg KOH/g, and was found to contain 14.0% phosphorus and 24.5% chlorine.

EXAMPLE 2

A reactor equipped with an agitator, thermometer, gas inlet and reflux condenser was charged with 1000 g of tris(2-chloroethyl)phosphate and 10 g of tris(2-chloroethyl)phosphite.

After 27 minutes of heating with the temperature at 50° C., 250 g of phosphorus pentoxide was added, with the exclusion of moisture and air.

The slurry was then heated to 115°-120° C. for 10 hours until the phosphorus pentoxide was dissolved. Ethylene oxide was then introduced to the mixture at 110°-120° C. until reaction ceased. This was indicated by a strong reflux of ethylene oxide on the side of the condenser. Two grams of stannous octoate was added and ethylene oxide was introduced to the solution at 110°-120° C. until reaction ceased.

Another 2 g of stannous octoate and 2 g of isopropanol were then added and ethylene oxide was again introduced until reaction ceased. The total time used for ethylene oxide addition was 171/2 hours.

The product was then stripped at 60° C. and 2 mm of Hg for 90 minutes.

1500 g of a water white liquid with a viscosity of 2600 cps (at 25° C.) and an acid number of 0.8 mg KOH/g was obtained. The product had a hydroxyl number of 13.5 mg KOH/g.

EXAMPLE 3

A reactor equipped with an agitator, thermometer, gas inlet and reflux condenser was charged with 1250 g of tris(dichloropropyl)phosphite. The solution was warmed to 130° C. and 110 g of P₂ O₅ was added. After 1 hour the P₂ O₅ had dissolved and oxygen gas was bubbled through the solution at 125°-135° C. over 3 hours. At this point 5 g of isopropyl alcohol was added, and ethylene oxide was introduced. After 4 hours, 2 g of stannous octoate was added and addition of ethylene oxide was resumed. After 4 more hours, 2 g of stannous octoate was again added, and the ethylene oxide reaction continued for another 2 hours. The product was cooled to 80° C. and stripped at 1 mm of Hg.

1450 g of a light yellow material with a viscosity of 34,000 cps (at 25° C.) and an acid number of 1.4 mg KOH/g was obtained. The product was found to have a hydroxyl number of 8 mg KOH/g, and to contain 9.2% phosphorus and 37.5% chlorine.

EXAMPLE 4

A reactor was charged with 600 pounds of tris(2-chloroethyl)phosphate and 6 lbs of tris 2(chloroethyl) phosphite. The mixture was then heated over 75 minutes to 43° C.; and 120 lbs of phosphorus pentoxide was added. The slurry was heated at 108° C. for 10 hrs. The batch was then cooled to 92° C. over 1 hour; then 2 lbs of tris(2-chloroethyl)phosphite was added. Over a 26 hour period a total of 162.5 lbs of ethylene oxide was added to the solution at 95°-105° C. with addition of 2.4 lbs of stannous octoate and 4.8 lbs of isopropyl alcohol to facilitate the reaction. The batch was then cooled to 45° C. and volatiles were removed at 5 mm of Hg for 2 hours. A total of 839 pounds of almost water white product with a viscosity of 1030 cps, an acid number of 0.8 mg KOH/g and a hydroxyl number 10.5 mg KOH/g was obtained. The product was found to contain 13.8% phosphorus and 26.7% chlorine.

EXAMPLE 5

A reactor equipped with an agitator, thermometer, gas inlet and reflux condenser was charged with 1300 g of tris(dichloropropyl)phosphate and 5 g of tris(2-chloroethyl)phosphite. With the temperature at 25° C., 175 g of phosphorus pentoxide was added with the exclusion of moisture and air.

The slurry was then heated for 4 hours at 80° C. A brown discoloration appeared and 5 grams more of tris(2-chloroethyl)phosphite was added to the system. The system was then heated for an additional 21/2 hours at 100°-110° C. until the phosphorus pentoxide dissolved.

Two grams of isopropyl alcohol was added and ethylene oxide was introduced to the mixture at 110°-120° C. until reaction ceased. This was indicated by a strong reflux of ethylene oxide on a dry ice condenser. Two more grams of isopropanol and 2 g of stannous octoate were added and ethylene oxide was introduced to the solution at 110°-120° C. until the reaction ceased.

The product was then stripped at 40° C. and 4 mm of Hg, yielding 1645 g of a pale orange liquid with a viscosity of 28,000 cps (at 25° C.) and an acid number of 0.8 mg KOH/g. The product has a hydroxyl number of 17.2 mg KOH/g and was found to contain 10.1% phosphorus and 37% chlorine.

EXAMPLE 4

A reactor equipped with an agitator, thermometer, gas inlet and reflux condenser was charged with 800 g of tris(2-chloroethyl)phosphate, 400 g of tris(dichloropropyl) phosphate and 10 g of tris(2-chloroethyl)phosphite. With the temperature at 27° C., 80 g of phosphorus pentoxide was added with the exclusion of air and moisture.

The slurry was then heated for 21/2 hours. Ethylene oxide was introduced to the mixture at 110°-120° C. until reaction ceased. This was indicated by a strong reflux of ethylene oxide in the condenser.

Two grams of isopropyl alcohol and 2 g of stannous octoate were added and ethylene oxide was introduced to the mixture at 110°-120° C. until the reaction ceased.

Two more grams of stannous octoate and 2 g of isopropanol were then added and ethylene oxide was introduced to the solution at 110°-120° C. until the reaction ceased.

The product was then stripped at 40° C. and 1 mm Hg, yielding 1340 g of a water white product with a viscosity of 1050 cps (at 25° C.) an acid number of 0.84 mg KOH/g and an hydroxyl number of 9.5 mg KOH/g. The product was found to contain 10.6% phosphorus and 35.8% chlorine.

EXAMPLE 7

A reactor equipped with an agitator, thermometer, gas inlet and reflux condenser was charged with 550 g of tris(dichloropropyl)phosphate, 800 g of tris(2-chloroethyl)phosphate and 10 g of tris(2-chloroethyl)phosphite. With the temperature at 25° C., 160 g of phosphorus pentoxide was added with the exclusion of moisture and air.

The slurry was then heated at 115°-120° C. for 6 hours until the phosphorus pentoxide had dissolved. Two grams of isopropyl alcohol was added and ethylene oxide was introduced to the mixture at 110°-120° C. until reaction ceased. This was indicated by a strong reflux of ethylene oxide in a dry ice condenser.

Two more grams of isopropanol and 2 g of stannous octoate were added and ethylene oxide was introduced to the solution at 110°-120° C. until the reaction ceased.

Another 2 g of stannous octoate was added and ethylene oxide was introduced to the solution at 110°-120° C. until the reaction ceased.

The product was then stripped at 50° C. and 2 mm/Hg, yielding 1666 g of an almost water white product with a viscosity of 1050 cps (at 25° C.) and an acid number of 1.12 mg KOH/g and an hydroxyl number of 95 mg KOH/g. The product was found to contain 11.6% phosphorus and 32.9% chlorine.

EXAMPLE 8

The composition prepared pursuant to Example 5 was incorporated at 9 p.h.r. into a flexible polyurethane foam having the following formulation:

    ______________________________________                                                         Parts by Weight                                                ______________________________________                                         oxypropylated glycerin                                                                           100.0                                                        silicone surfactant                                                                              1.0                                                          triethylenediamine catalyst                                                                      0.1                                                          N--ethyl morphiline                                                                              0.2                                                          water             4.0                                                          stannous octoate catalyst                                                                        0.2                                                          tolylene diisocyanate                                                                            50.67                                                        ______________________________________                                    

The foam mixture was poured into an open-top box and allowed to expand into a 15 inch square block. It was then oven cured at 130° C. for about 10 minutes. This was followed by ambient temperature curing for 3 days.

Flammability testing was conducted pursuant to the California Vertical burn test and Motor Vehicle Safety Standard 302 (MVSS-302). A control foam of the same formulation without the flame retardant was also prepared and tested for flammability.

Particulars on the California Vertical burn test are available from the State of California in Technical Information Bulletin 117. In the MVSS-302 test, a specimen of foam 4"×1/2" thick by 14" long is held horizontally between two U-shaped brackets which allow free access of air above and below. The specimen is ignited by a bunsen burner and the burning rate in inches per minute is measured. A burn rate below 4"/min. is usually required.

General Motors Corporation uses the following qualitative measures under MVSS-302:

    ______________________________________                                         Does not ignite       DNI                                                      Self extinguishes (SE) before first                                                                  SE                                                       mark (before 11/2" total)                                                      SE in less than 31/2" total                                                                          SE/NBR                                                   SE after 31/2" from starting point                                                                   SE,α burn rate                                     Burns full length     burn rate                                                ______________________________________                                    

The flammability results were as follows:

    ______________________________________                                                              FLAME RETARDED                                                        CONTROL  FOAM                                                      ______________________________________                                         MVSS-302                                                                       INITIAL RATING                                                                               BURN       SE/NBR                                                Avg In Burned 11.50      1.46                                                  Avg Sec Burned                                                                               130.00     0.50                                                  Burn Rate     4.63                                                             DHA* RATING   BURN       SE/NBR                                                Avg In Burned 9.90       1.15                                                  Avg Sec Burned                                                                               107.89                                                           Burn Rate     4.92                                                             CALIF. VERTICAL                                                                INITIAL RATING                                                                               FAIL       PASS                                                  Avg In Burned 12.00      2.45                                                  Avg Sec Burned                                                                               9.20                                                             DHA*RATING    FAIL       PASS                                                  Avg. In Burned                                                                               12.00      2.75                                                  Avg Sec Burned                                                                               9.60                                                             ______________________________________                                          *Dry heat aging for 22 hours at 140 ° C.                          

EXAMPLE 9

The composition prepared pursuant to Example 6 was incorporated at 10 p.h.r. into a flexible polyurethane foam having the same formulation and physical characteristics as that described in Example 8. The control foam of Example 8 was used as a reference.

Flammability testing results were as follows:

    ______________________________________                                                              FLAME RETARDED                                                        CONTROL  FOAM                                                      ______________________________________                                         MVSS-302                                                                       INITIAL RATING                                                                               BURN       SE/NBR                                                Avg In Burned 11.50      1.19                                                  Avg Sec Burned                                                                               130.00                                                           Burn Rate      4.63                                                            DHA RATING    BURN       SE/NBR                                                Avg In Burned  9.90      1.32                                                  Avg Sec Burned                                                                               107.80     0.20                                                  Burn Rate      4.92                                                            CALIF. VERTICAL                                                                INITIAL RATING                                                                               FAIL       PASS                                                  Avg In Burned 12.00      2.15                                                  Avg Sec Burned                                                                                9.20                                                            DHA RATING    FAIL       PASS                                                  Avg In Burned 12.00      2.55                                                  Avg Sec Burned                                                                                9.60                                                            ______________________________________                                    

Having set forth the general nature and some examples of the present invention, the scope is now specifically set forth in the appended claims. 

What is claimed is:
 1. A flexible polyurethane foam having a flame retardant effective amount of an oligomeric phosphate ester composition of the structural formula: ##STR21## wherein R is C₁ -C₁₀ alkyl or C₁ -C₁₀ haloalkyl; R¹ and R² are the same or different and are hydrogen, C₁ -C₁₀ alkyl or C₁ -C₁₀ haloalkyl and n is an integer from 2 to about 10; said oligomeric phosphate ester composition having been prepared by first reacting P₂ O₅ with a trialkyl or tris(haloalkyl)phosphate of the structural formula: ##STR22## wherein R is the same as defined above, at a temperature from about 0° C. to about 200° C. in the presence of about 0.01% to about 5% of a phosphite of the structural formula:

    P(OR).sub.3

wherein R is as defined above; followed by reacting the intermediate produced by the first reaction with an excess of an epoxide of the structural formula: ##STR23## wherein R¹ and R² are as defined above, at a temperature from about 0° C. to about 200° C.
 2. The composition of claim 1 wherein R is selected from the group consisting of methyl, ethyl, propyl, isopropyl, straight or branched butyl, chloroethyl, chloropropyl, chloroisopropyl, dichloroethyl, dichloroisopropyl, dichloropropyl, bromoethyl, bromopropyl, bromoisopropyl, dibromoethyl, dibromoisopropyl and dibromopropyl.
 3. The composition of claim 1 wherein R¹ and R² are the same or different and are selected from the group consisting of hydrogen, methyl, ethyl, propyl, isopropyl, straight or branched butyl, chloromethyl, chloroethyl, chloropropyl, chloroisopropyl, dichloroethyl, dichloropropyl, dichloroisopropyl, bromoethyl, bromoethyl, bromopropyl, bromoisopropyl, dibromoethyl, dibromopropyl and dibromoisopropyl. 